1993 EZGO Golf Cart - Gonk's Cartzilla build.

Hello all. First time poster to this forum and kinda nervous I stay within the rules here. I could actually be posting in 4 or 5 topics on this board, but I'm not ready to ask a lot of questions yet.

I figured I should start a worklog for placing my equipment and setup. I'm sure I'll have specific questions once I get deeper into the install. If I can't search out answers this worklog will show others what I have specifically done. If they care to help with my questions.

Now down to the nitty gritty.

I have a 1993 EZGO 36 volt electric golf cart, which I'm pretty deeply into fabbing already. I have my own website dedicated to the cart build and everyone is welcome to check it out. There are no advertisements or anything like that. Just a guy with a site www.gonkulor.com

I have trunked an extra 12v battery with plans for 2 12v trolling motor batteries run in parallel. This Friday I will be getting a Lilliput 7" - 10" touchscreen monitor and possibly a VoomPC-2 if all bills get paid.

My plans are aggressive and could take me into next year, 2013 due to time and cost. In order of importance my plan is as follows;
1. Get monitor mounted in dash and water resistant, if not waterproofed.
2. Finish body work
3. get basic carputer running
4. finish body work
5. Install music amplifier and speakers
6. fix leaking EMF/RF from DC motor as necessary
7. add wifi/internet access
8. install underfloor, wheel well and cab led lighting

9. use arduino to control led's
10. finish body work
11. install gps navigation hardware/software
12. more arduino for gps
13. install hydraulic brakes
14. finish body work
15. install clutchable rotary motor to steering
16. tweak remote control autopilot to bring me home from the bar.
17. hopefully have the bodywork finished someday :lol:

So, Item 1. is to mount the monitor and it will go here.
http://www.gonkulor.com/files/dash/2...2020.41.59.jpg

I had to remove the ball holder and cup holders. I don't have any console yet and have to incorporate the monitor into something that will work as a console. I should have more to post in a week or so, unless someone adds comments or interest.

Best Regards
Gonk

Welcome to the forum! You have got quite a project there. Good luck in your adventure. SNO

Love it. One question? How long is this going to run on battery?

Quote:

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Originally Posted by dmcdlrn

Love it. One question? How long is this going to run on battery?

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Thanks SNO and dmcdlrn. To answer your question dmcdlrn, maybe 6 hours in a day. I have to charge the cart nightly and I plan to make one more quick disconnect charge receptical for the 12 volt pack. If I can't find maintenance type "12v trolling motor" batteries I will get 2 12v golf cart batteries. The trolling and golf cart batteries are meant for the slow drain.

I see I forgot to add sound amplifier and speakers to my list in OP. I should edit my list and also add the troubles I expect from the DC motor EMF/RF.

Box =

Intel D525MWV Atom Mini-ITX VoomPC-2 Car PC,2GB,M2-ATX, with dual bluetooth/wifi.
Monitor = Lilliput EBY701-NP/C/T
10-Gang ATO/ATC Marine Fuse Block
4-Gang AGC Marine Fuse Block
4 I/O 8 Gauge Distribution Block

I installed a hard drive from a defunct laptop laying around. Put Win7 Ultimate 32bit on it. The system booted up properly. Wireless connected and updates installed.

Attachment 66185 The amp in the background is 20 years old and very power hungry, it pulled my battery to 7 volts in about 3 hours. The amp quit but the PC was still running, monitor was acting flakey. I will purchase a more modern and power conservative amp.

I fab'd a hard mount for the monitor. I'll get to put some trim and shape into the dash after I install more components
Attachment 66186

Attachment 66187

Attachment 66188

So everything is installed but not completely mounted. Only issue I have is losing my WiFi after waking from hibernation. The WiFi issue is either my switchology/configuration or after taking the cart for a 10 mile run the PCI-E Wifi card jarred loose. I'm voting on the card becoming loose because I wasn't tickled with how cheesy it is mounted on the mainboard. Next time I pull the dash off I'll open up the box and reinstall the card with a couple dollops of silicon sealant on the securing click posts.

LED RGB lights are in work. I'm in communication with the guy who will modify his hardware's firmware so I can turn on and off all my lights, including the headlights, running lights, brakes, and blinkers. His only advice for me is to make sure I have enough 12v and 5v current for all the lights. He said I need power conditioning. Would another M4 or pico unit work? He also mentioned at least a voltage clamp, I haven't googled that yet.

I'm also in communication with a seller to custom make me some brighter H4 LED headlight bulbs. he said they would be 12 watts each.

I think that is all for now until I get more hardware.

Gonk

I haven't updated in awhile so I figured I should catch up on my progress.

Attachment 66782Network switch

Attachment 66783LOR LED light controller

Attachment 66791J1 LED light controller

Attachment 66784two 500w 36v to 12v DC converters

Attachment 66785ANN current limiters

Attachment 66786wires, fuses

Attachment 66787same same

Attachment 66788Ram upgrade for puter, now I can install 64bit

Attachment 66789Marine amp

Attachment 66790Marine speakers

More updates

Attachment 6679210 pounds of crap in a 5 lb bag

Attachment 66793Starting my power distribution

Attachment 66794

Attachment 66809basic installation and testing

Attachment 66808

Attachment 66807

Attachment 66806

Attachment 66805

Attachment 66804

Attachment 66803

Attachment 66802

Attachment 66801

Attachment 66800

Attachment 66799

Attachment 66798

Attachment 66797

Attachment 66796

Attachment 66795this is the old computer case I cut up. I made the shelving for mounts from this.

Attachment 66810Started running wires.

After all wires were ran, I calculated I installed more than 300 feet of new wire.

Last update for now.

Attachment 66811Finished my test panel

Attachment 66812All of my LED pixel lights showed up

Attachment 6681312watt 18SMT LED headlight bulbs showed up. These are H4 socket bulbs

Attachment 66814Finished my dashboard fab. I still need bondo and finish. The finishing will be awhile before I can get to that. I have primed everything to stop the rusting though.

And now this morning I went outside to do more geek work with the computer and the dew on the monitor zuzzed the picture. Hopefully once the dew dries off the monitor it will still work.

Gonk

I said I calculated 300+ feet of new wire. These pictures might back that up.

Attachment 66815

Attachment 66816

Attachment 66817

Attachment 66818

Attachment 66819 This is just insane. I had 160 solder joints to do all with 26 gauge wire. Ewww. Oh ya, these are for front grille pixel lighting.

you can definitely claim to be the first and only golf cart in the world running windows......

some crazy amount of wires there. i'm anxious to see what this pixel lighting on your grill is going to look like.

nice build, keep the updates coming!